System and method for making extruded, composite material

ABSTRACT

Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.

CROSS-REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 10/285,449 filed Nov. 1, 2002, which is incorporated byreference herein in its entirety.

NOTICE OF COPYRIGHT PROTECTION

A portion of the disclosure of this patent document and its figurescontain material subject to copyright protection. The copyright ownerhas no objection to the facsimile reproduction by anyone of the patentdocument, but otherwise reserves all copyrights whatsoever.

FIELD OF INVENTION

The invention disclosed herein relates to composite materials ingeneral, and more particularly, to an apparatus for and method of makingan extruded, cellulosic-based composite material.

BACKGROUND

Manufacturing processes invariably result in material waste for avariety of reasons, such as imperfections in raw materials and errorsmade during production. Material waste has increasingly become aneconomic burden for manufacturers of wood products, such as doors andwindows. In the past, wood waste from doors, cardboard, particleboard,and wood pallets was either disposed of in landfills or burned. Thesteady increase in fees for landfill disposal and increasingly stringentair-quality regulations have made traditional methods of waste disposalproblematic for manufacturers of wood products.

Conventional alternatives to landfill disposal and burning areinadequate. One alternative is to place any one of a variety ofpollution-control devices in the exhaust path of a wood-burning plant.However, the cost of such devices is expensive, and for smallmanufacturers, these expenses can quickly become cost-prohibitive. Thecost of burning waste can also include governmental permit fees, as wellas the cost of ensuring compliance with environmental regulations.

An alternative to disposing of the waste is to find another market forthe waste material. One potential market is animal bedding. However,animal bedding requires generally homogenous and nontoxic material. Woodwaste from manufacturing processes can often include ferrous materialsand painted products, which can be harmful to animals. Thus, animalbedding is often not an adequate solution. Another potential market isfill material for construction sites. The construction industry utilizesfill for a variety of purposes, such as raising elevations. However, thedemand for fill material is inconsistent, which means that manufacturerswould be forced to keep an inventory of waste when there is no adequatedemand. Keeping any sort of inventory is generally expensive, and thus,this option does not offer sufficient economic advantages over disposal.

Another alternative to disposing of wood waste is to utilize the woodwaste to manufacture composite components. Various methods for utilizingwood waste to make certain wood-based composite materials, such ascertain particleboards and fiberboards, is well known in the art.However, the equipment currently available to manufacture such compositematerials is relatively expensive, and therefore is cost-prohibitive formost small and specialty manufacturers. Moreover, currently-availablewood extrusion processes require generally uniform—that is, size, shape,weight, moisture content, and material type—raw materials. Often, woodwaste from manufacturing processes is not uniform. Moreover, the productproduced by such conventional methods typically has a density that isnon-uniform.

SUMMARY OF THE INVENTION

The present invention includes systems and methods for making extrudedcomposite material, and products made therefrom. One embodiment of thepresent invention provides for a method of making a material compositionthat includes mixing a thermoset polymer, a petroleum distillate, arelease agent, and a catalyst to form an admixture. Preferably, thethermoset polymer is present in the furnish in an amount ofapproximately 6 to approximately 10 percent by weight. The method alsoincludes mixing the admixture with a cellulosic material to form agenerally homogenous furnish.

Another embodiment of the method includes introducing the furnish into adie having a length. The method further includes heating the furnish inthe die to a temperature of at least 212 degrees F., forming a watervapor in the furnish, and releasing the water vapor from the furnish andthe die.

One embodiment of the present invention provides an apparatus forforming a continuous cellulosic-based composite material that includes amixing chamber, a feeding chamber, and a die. The mixing chamberincludes a volume and at least one entrance and one exit. The feedingchamber includes a volume, an entrance, and an exit. The entrance of thefeeding chamber is in fluid communication with the exit of the mixingchamber.

The die includes an entrance, an exit, a piston, a ram, and a pressingchamber. The entrance of the die is a fluid communication with the exitof the feeding chamber. The pressing chamber has a volume formed byfirst and second platens. The first and second platens are in facingopposition to one another and have a length extending continuously fromat least the entrance of the die to the exit of the die. The first andsecond platens have a plurality of orifices and heating elementsdisposed along the length. The first and second platens are disposed infirst and second positions. The first position forms a first volume andthe second position forms a second volume.

One embodiment of the present invention provides a material compositionthat includes a cellulosic material, a thermoset polymer being presentin the composition in an amount of approximately 6 to approximately 10percent by weight, a petroleum distillate, a release agent, and acatalyst. The composition has a generally uniform density. In anembodiment, the cellulosic material includes discrete wood particleshaving a diameter of less than approximately one-eighth of an inch. Inother embodiment, the cellulosic material includes discrete woodparticles having a diameter of less than approximately three-eighths ofan inch. The cellulosic material is present in the composition in anamount of approximately 83 to approximately 93.5 percent by weight. Inan embodiment, the thermoset polymer is a melamine urea formaldehyderesin. The petroleum distillate is present in the composition in anamount of approximately 0 to approximately 2 percent by weight. Therelease agent can be present in the composition in an amount ofapproximately 0.03 to approximately 0.5 percent by weight. The catalystcan be present in the composition in an amount of approximately 0.5 toapproximately 3 percent by weight: In an embodiment, the composition hasa density in a range between approximately 27 and approximately 36pounds per cubic foot (pcf).

An advantage of the present invention can be to provide a homogenouscomposite material composition.

One advantage of the present invention can be to utilize non-uniform rawwaste materials for the composite material composition.

An advantage of the present invention can be to reduce the amount ofwaste disposed of in landfills or burned by using waste wood to form acomposite material.

Another advantage of the present invention can be to provide a uniform,high density composite material composition.

Yet another advantage of the present invention can be to providecomposite material composition that is an effective sound barrier.

A further advantage of the present invention can be to provide aninexpensive apparatus for manufacturing a composite materialcomposition.

Yet a further advantage of the present invention can be to provide fordrying a composite admixture integral to the apparatus.

Another advantage of the present invention can be to use the materialfor components in hollow-core wood doors.

Additional advantages of embodiments of the invention are set forth inthe detailed description that follows and will become more apparent tothose skilled in the art upon examination of the following.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, assist in illustrating embodiments of theinvention.

FIG. 1 is a schematic of an apparatus for forming a continuouscellulosic-based composite material according to an embodiment of theinvention.

FIG. 2A is a top plan view of a first platen of the apparatus of FIG. 1.

FIG. 2B is a side view of the first platen of the apparatus of FIG. 1.

FIG. 2C is a bottom plan view of the first platen of the apparatus ofFIG. 1.

FIG. 2D is a cross-sectional view at line 2D-2D in FIG. 2C.

FIG. 2E is a cross-sectional view at line 2E-2E in FIG. 2C.

FIG. 2F is a cross-sectional view at line 2F-2F in FIG. 2A.

FIG. 3A is a top plan view of a second platen of the apparatus of FIG.1.

FIG. 3B is a side view of the second platen of the apparatus of FIG. 1.

FIG. 3C is a side view of a platen spacer of the apparatus of FIG. 1.

FIG. 3D is a top plan view of the platen spacer of the apparatus of FIG.1.

FIG. 3E is a cross-sectional view at line 3E-3E in FIG. 3A.

FIG. 3F is a cross-sectional view at line 3F-3F in FIG. 3A.

FIG. 4A is a side view of a ram and cylinder assembly of the apparatusof FIG. 1

FIG. 4B is a side view of the ram of the apparatus of FIG. 1.

FIG. 4C is another side view of the ram of the apparatus of FIG. 1.

FIG. 5 is a flowchart of a process of using the apparatus in FIG. 1.

FIG. 6 is a front view of a door using the material composition producedby the process of FIG. 5.

DETAILED DESCRIPTION

The present invention includes systems and methods for making extrudedcomposite material, and products made therefrom. FIG. 1 shows oneembodiment of a system for making extruded composite material accordingto the present invention. Referring to FIG. 1, a schematic of anapparatus 100 for forming a continuous cellulosic-based compositematerial according to an embodiment of the invention is shown. Theapparatus 100 shown includes a mixing chamber 200, a feeding chamber300, and a die 400. The mixing chamber 200 includes a volume 210, afirst entrance 220, a second entrance 230, an exit 240, and an auger270. A homogenous furnish (not shown), which includes a cellulosicmaterial (not shown) and an admixture (not shown), is formed in thevolume 210 of the mixing chamber 200. The admixture includes a thermosetpolymer, a petroleum distillate, a release agent, and a catalyst.Alternatively, any suitable thermoset polymer, petroleum distillate,release agent, and catalyst can be used.

The volume 210 of the mixing chamber 200 is formed by a plurality ofmixing chamber walls 260. The auger 270 is disposed proximate the exit240 of the mixing chamber 200. The auger 270 forms the homogenousfurnish by blending the cellulosic material and the admixture, i.e.,directly contacting the cellulosic material and the admixture. Themixing chamber 200 includes a chiller 250. Preferably the chiller 250 isdisposed separate from the volume 210 of the mixing chamber 200.Alternatively, the chiller 250 can be formed integrally with the volume210 of the mixing chamber 200.

The feeding chamber 300 includes a volume 310, an entrance 320, and anexit 330. The entrance 320 of the feeding chamber 300 is in fluidcommunication with the exit 240 of the mixing chamber 200. The auger 270mechanically conveys the homogenous furnish through the mixing chamber200 to the exit 240 of the mixing chamber. The furnish is gravity-fed tothe entrance 320 of the feeding chamber 300. Alternatively, any othersuitable conveying means can be used.

The die 400 includes an input chute 410, an output channel 420, a piston430, a ram 460, and a pressing chamber 440. The pressing chamber 440 hasa volume 442. The volume 442 of the pressing chamber 440 is formed by afirst platen 470 and a second platen 480. Alternatively, there can bemore than two platens. The first platen 470 and the second platen 480are in facing opposition to one another and each have a length extendingcontinuously from at least the input chute 410 to the output channel420. In one embodiment, the length of the first platen 470 and thesecond platen 480 is 12 feet. Alternatively, the platens 470 and 480 canbe formed of a series of smaller plates disposed along a length of thepressing chamber 440. Preferably, the first platen 470 and the secondplaten 480 are formed of ASTM A36 steel plate. Alternatively, the firstplaten 470 and the second platen 480 can be formed of any other suitablegrade of steel.

Referring now to FIG. 2A, a top view of the first platen 470 is shown.In one embodiment, the first platen 470 is 12 feet long, four feet wide,and three inches thick. Alternatively, any other suitable dimensions canbe used. The first platen 470 includes a top surface 471. Disposedthroughout the top surface 471 is a plurality of orifices 472. Theorifices 472 are formed through the entire thickness of the first platen470. Preferably, the orifices 472 are formed by drilling through thefirst platen 470. Alternatively, the orifices 472 can be molded in thefirst platen 470. A diameter of the orifices 472 are in a range between0.30 inches and 0.60 inches. The orifices 472 permit vapor to escape thedie 400 through the first platen 470. Disposed substantially along aperimeter is a plurality of bolt holes 494.

Disposed along a side surface of the first platen 470 is a plurality ofhinges 473. Preferably, the hinge 473 is welded to the side surface ofthe first platen 470. Alternatively, the hinge 473 can be attached byfastening or the hinge 473 can be formed integrally with the firstplaten 470. FIG. 2F shows a side view of one of the hinges 473 in across-sectional view of the first platen 470 taken at line 2F-2F in FIG.2A.

In an embodiment, the hinge 473 projects six-and-one-half inches fromthe side surface of the first platen 470. The thickness of each of thehinges 473 is three-quarters of an inch. The hinges 473 are generallyflush with the top surface 471 of the first platen 470. An attachingorifice 479 is formed in a lower portion of each of the hinges 473. Adiameter of the attaching orifice 479 is preferably eleven-sixteenths ofan inch.

Referring now to FIG. 2B, a side view of the first platen 470 is shown.The first platen 470 includes a plurality of match drilled holes 474. Asshown in FIG. 2B, the match drilled holes 474 are drilled into a sidesurface 475 of the first platen 470. The match drilled holes 475 areformed by a series of four minor diameters forming a square-like shapeand a major diameter disposed in a center of the square. Preferably, theplurality of match drilled holes 474 is 20. The major diameter of eachof the match drilled holes 474 is drilled entirely from the side surface475 to an opposite side surface (not shown). In an embodiment, the majordiameter of the match drilled holes 474 is one inch and the minordiameters of the match drilled holes 474 are one-half an inch.Alternatively, any other suitable dimensions can be used for the majorand minor diameters of the match drilled holes 474. The match drilledholes 474 supply hot oil to the first platen 470 to heat the furnish inthe die 400 (described in more detail below).

Referring now to FIG. 2C, a bottom view of the first platen 470 isshown. The first platen 470 includes a bottom surface 476. Disposedalong the bottom surface 476 of the first platen 470 are a plurality ofgrooves 477. The grooves 477 are disposed substantially parallel to oneanother and extend nearly the entire distance from the side surface 475to the opposite side surface. Preferably, the grooves 477 can bemachined into the bottom surface. Alternatively, the grooves 477 can beetched or molded in the bottom surface 476. Disposed within the grooves477 are the orifices 472. Referring now to FIG. 2D, a cross-sectionalview taken along line 2D-2D in FIG. 2C shows a typical detail of theorifices 472. The orifice 472 shown in FIG. 2D extends through the firstplaten 470 from the top surface 471 to the bottom surface 476.

In one embodiment, an infeed 478 is disposed in the top surface 471. Theinfeed 478 is generally rectangular in shape and extends substantiallyfrom the side surface 475 to the opposite side surface. Across-sectional view of the infeed 478 taken along line 2E-2E in FIG. 2Cis shown in FIG. 2E. The infeed 478 extends through the entire thicknessof the first platen 470. Preferably, a width of the steam vent 478 isfive inches. Alternatively, any other shape and dimensions can be used.The infeed 478 allows furnish to enter the die 400.

Referring now to FIG. 3A, a top view of the second platen 480 is shown.In one embodiment, the second platen 480 is 12 feet long, four feetwide, and three inches thick. Alternatively, any other suitabledimensions can be used. The second platen 480 includes a top surface481. Disposed throughout the top surface 481 is a plurality of orifices482. The orifices 482 are formed through the entire thickness of thesecond platen 480. Preferably, the diameter of the orifices 482 are in arange between 0.30 inches and 0.60 inches. A cross section of the secondplaten 480 taken along line 3E-3E in FIG. 3A shows one of the orifices482 in FIG. 3E. The orifices 482 permit vapor to escape the die 400through the second platen 480. A plurality of grooves 484 are disposedalong the bottom surface 481 of the second platen 480. The grooves 484are disposed substantially parallel to one another and extend nearly theentire distance from a side surface 485 to an opposite side surface (notshown). The plurality of orifices 482 are disposed within the grooves484. A plurality of hinges 483 are disposed along a side surface of thesecond platen 480. The details of the hinges 483 are materially similarto the hinges 473 and will not be described in detail. The hinges 483are shown in FIG. 3F. The hinges 473 and 483 interlock to secure thefirst and second platens 470 and 480 together. The hinges 473 and 483can be interlocked together by a nut and bolt or any other suitablesecuring means.

Referring now to FIG. 3B, a side view of the second platen 480 is shown.Preferably, the second platen 480 is three inches thick. The secondplaten 480 includes a plurality of match drilled holes 486. The matchdrilled holes 486 are drilled into the side surface 485 from the sidesurface 485 to the opposite side surface. The match drilled holes 486supply hot oil to the second platen 480 to heat the furnish in the die400 (described in more detail below). The structure of the match drilledholes 486 in the second platen 480 is similar in material respect to thematch drilled holes 474 of the first platen 470, and thus will not bedescribed in detail.

Referring now to FIGS. 3C and 3D, a platen spacer 490 is shown.Preferably, the length of the platen spacer 490 corresponds to thelength of the first and second platens 470 and 480, i.e., 12 feet.Alternatively, the length of the platen spacer 490 can be different thanthe length of the first and second platens 470 and 480. A width of theplaten spacer 490 is preferably six-and-seven-eighths inches.Alternatively, the width of the platen spacer 490 can be approximatelysix-and-seven-eighths inches or any other suitable thickness. In oneembodiment, a thickness of the platen spacer 490 is tapered. At an end492 of the platen spacer 490 proximate the output channel 420, thethickness is preferably 1.19 inches. At an end 491 of the platen spacer490 proximate the infeed 478, the thickness is preferably 1.11 inches.In the embodiment, the thickness of the platen spacer 490 is 1.11 inchesfor six feet from end 491; the thickness of the spacer 490 thenincreases gradually to 1.19 inches over the next two feet, and remainsat 1.19 inches to the end 492. Alternatively, any other suitabledimensions and configurations can be provided. For example, in anotherembodiment, the thickness of the platen spacer 490 at the end 492 can be1.75 inches. In this other embodiment, the thickness of the platenspacer 490 can be 1.67 inches at the end 491 and for six feet from theend 491. Alternatively, the platen spacer 490 can be any other suitablethicknesses. The platen spacer 490 can also have a constant thicknessalong its entire length.

In an embodiment, the spacer 490 is disposed between the top surface 481of the second platen 480 and the bottom surface 476 of the first platen470. Preferably, a plurality of bolts (not shown) join the first platen470, the second platen 480, and the spacer 490 through the plurality ofbolt holes 494. As the spacer 490 is attached to the first and secondplatens 470 and 480, the first and second platens 470 and 480 conform tothe spacer 490. Preferably, there are two spacers 490. One spacer 490 isdisposed along side surfaces 475 and 485 and the opposite side surfaces.The spacers 490 also prevent furnish from escaping through sides of thedie 400.

Preferably, the first and second platens 470 and 480 are separated bythe spacer 490. Due to the taper of the spacer 490, the distancesbetween the platens 470 and 480 vary, and thus, the volume 442 of thepressing chamber 440 varies as well. In a position proximate the inputchute 410, the platens form a first volume (not shown) of the pressingchamber 440. In a second position proximate the output channel 420, theplatens form a second volume (not shown) of the pressing chamber 440.The first volume is less than the second volume. Preferably, the minimumdistance between the platens 470 and 480 is 1.11 inches—the thickness ofthe spacer 490 at end 491. Preferably, the maximum distance between theplatens 470 and 480 is 1.19 inches—the thickness of the spacer 490 atend 492. Alternatively, any other suitable distances between the platens470 and 480 can be provided. For example, the maximum distance betweenthe first and second platens 470 and 480 can be 1.75 inches. Thismaximum distance between the platens 470 and 480 can be proximate theoutput channel 420. In another embodiment, the distance between theplatens 470 and 480 can be uniform through the length of the pressingchamber 400. The furnish is compressed as it is displaced from the inputchute 410 to the output channel 420.

The first and second platens 470 and 480 include a plurality of heatingelements 450 disposed along the length of the first and second platens470 and 480. Each heating element 450 is formed by a number of theplurality of match drilled holes 474 and 486. Preferably, each heatingelement 450 is formed by five of the match drilled holes 474 in thefirst platen 470 and five of the match drilled holes 486 in the secondplaten 480. Preferably, the heating elements 450 supply hot oil to theplatens 470 and 480. Alternatively, the heating elements 450 can beformed of any suitable heating element, including electricresistance-type heaters. The preferably five heating elements 450 can becontrolled with respect to temperature by increasing or decreasing themajor diameter of the match drilled holes 474 and 486. As describedabove, the preferred major diameter is one inch. The heating element 450proximate the infeed 478 is preferably maintained at a temperature in arange between 13 approximately 340 degrees F. and approximately 360degrees F. The heating element 450 proximate the output channel 420 ispreferably maintained at a temperature in a range between approximately360 degrees F. and 380 degrees F. The heating elements 450 between thesetwo extremes are maintained at a temperature between the extremes of thetemperature ranges described above. The heating elements 450 transfersufficient heat to the homogenous furnish in the die 400 to vaporizewater in the furnish, i.e., to at least 212 degrees F.

The heating elements 450 shown are provided with hot oil by a hot oilpump 452. The hot oil pump 452 preferably includes an integral hot oilreservoir (not shown) and an integral hot oil heater (not shown).Alternatively, the hot oil pump 452 can be connected to a stand-alone(i.e., separate) hot oil reservoir (not shown) and a stand-alone hot oilheater (not shown). A feed line 454 transports the hot oil to theheating elements 450 and a return line 456 transports cooled oil to thepump 452 for re-heating and subsequent recirculation.

In an embodiment shown in FIG. 1, the piston 430 is disposed proximatethe input chute 410 and opposite the output channel 420. The piston 430is positioned substantially perpendicular to the input chute 410.Preferably, the piston 430 is powered by a hydraulic oil pump 432.Alternatively, the piston 430 can be powered by any other suitablemeans, such as pneumatic or motorized means and exerts a force in thevolume 442 of the pressing chamber 440 in a generally planar directionfrom the input chute 410 toward the output channel 420. The force of thepiston 430 is preferably in a range between approximately 1000 poundsper square inch (psi) and 2500 psi. The force of the piston 430displaces the furnish toward the output channel 420. Preferably, thepiston 430 cycles 15 times per minute.

Referring now to FIG. 4A, a detail of an embodiment of the piston 430 isshown. The piston 430 is connected to a ram 460. Preferably, the piston430 is connected to the ram 460 by a clevis 432. Alternatively, anyother suitable connecting means can be provided.

Referring now to FIG. 4B, a side view of the ram 460 is shown. In theembodiment shown in FIG. 4B, the ram 460 is approximately 32 inches byapproximately 34 inches. Alternatively, other suitable dimensions can beused. The ram includes an end 462 and a serrated face 464. Preferably,the serrated face 464 is approximately 1.1 inches by approximately 34inches. Alternatively, any other suitable dimensions can be used.Disposed between the end 462 and the serrated face 464 is a body 466.The body 466 includes a plurality of wear strips 468. In one embodiment,several wear strips 468 are disposed proximate the serrated face 464.Several other wear strips 468 are disposed perpendicular to the end 462and the serrated face 464. The wear strips can be attached to the faceby a plurality of fasteners (not shown). Preferably, the serrated face464 forms a jagged surface. Alternatively, the serrated face 464 can bea generally smooth surface.

Referring now to FIG. 4C, another side view of the ram 460 is shown. Inan embodiment shown in FIG. 4C, the end 462 is formed of two plates 463.The two plates 463 are joined to the body 466. The two plates 463 can bejoined to the body 466 by welding or by fastening. Alternatively, thetwo plates 463 can be formed integrally with the body 466. The thicknessof the end 462 is preferably two-and-one-half inches. The thickness ofthe body is approximately 1.1 inches. A plurality of bushings 465 areformed or drilled through the entire thickness of the end 462.Preferably, an inner diameter of the bushings 465 isone-and-three-quarters inch and an outer diameter of the bushings 465 istwo-and-one quarter inches. Alternatively, any other suitable diameterscan be provided. The plurality of bushings 465 provides a means ofattachment for the clevis 432 to couple the piston 430 and the ram 460.Thus, the force of the piston 430 is transferred to the ram 460.

The ram 460 displaces the furnish in the pressing chamber 400. Thepressing chamber is formed by the first platen 470, the second platen480, and the platen spacer 490. The movement of the furnish through thepressing chamber compresses the furnish to a predetermined density.Preferably, the density of the furnish is in a range between 27 and 36pcf. Preferably, the ram 460 displaces the furnish through the die at arate of 990 pounds per hour. Alternatively, any other suitable rate canbe used.

An embodiment of the apparatus also includes a hopper 500 and a resininjector 600. The hopper 500 includes a volume 510, an entrance 520, anexit 530, and a screw feeder 540. The volume 510 of the hopper 500 isformed by a plurality of hopper walls 550 and holds the cellulosicmaterial. The screw feeder 540 is disposed proximate the exit 530 of thehopper 500. The exit 530 of the hopper 500 is in fluid communicationwith the first entrance 220 of the mixing chamber 200. The screw feeder540 continuously introduces the cellulosic material from the exit 530 ofthe hopper 500 to the first entrance 220 of the mixing chamber 200 at arate in a range between approximately 800 and approximately 1300 poundsper hour. Alternatively, a faster or slower rate can be used.

An embodiment of the hopper 500 also includes a screen (not shown)disposed in an upper portion of the hopper 500 between the entrance 520of the hopper and the screw feeder 540. Thus, the screen separates theentrance 520 of the hopper 500 and the exit 530 of the hopper. Mostpreferably, the screen is one-eighth-of-an-inch thick. Preferably, thescreen is three-eighths-of-an-inch thick. Alternatively, any othersuitable thickness can be used for the screen. A plurality of orifices(not shown) is disposed in the screen. Most preferably, a diameter ofeach of the orifices is one-eighth-of-an-inch, also known as U.S. mesh#6. Preferably, the diameter of each of the orifices isthree-eighths-of-an-inch. Alternatively, any suitable diameter can beprovided. Thus, the screen prevents cellulosic material having adiameter greater than or equal to the screen orifice diameter frompassing through the exit 530 of the hopper 500.

The resin injector 600 includes a plurality of tanks 610 holding theadmixture. The tanks 610 include a thermoset polymer tank 612, a releaseagent tank 614, a petroleum distillate tank 616, and a catalyst tank618. Preferably a capacity of the thermoset tank 612 is 3,000 gallons, acapacity of the release agent tank 614 is 250 gallons, a capacity of thepetroleum distillate tank 616 is 1,000 gallons, and a capacity of thecatalyst tank is 250 gallons. Alternatively, any suitable number,capacities, and configurations of tanks can be provided.

The resin injector 600 also includes a resin valve 630. The resin valve630 is in fluid communication with and can be disposed proximate thesecond entrance 230 of the mixing chamber 200. The resin valve 630regulates the flow of the admixture from the tanks 610 into the mixingchamber 200. Preferably, the admixture enters the mixing chamber 200 ata rate in a range between 0.15 and 0.35 gallons per minute.Alternatively, the admixture can enter the mixing chamber 200 at anyother suitable rate. The admixture is sprayed onto the cellulosicmaterial in the volume 210 of the mixing chamber 200. Preferably, priorto entering the mixing chamber 200, the thermoset resin, the releaseagent, and the petroleum distillate are mixed in a mixing tank 620forming a blend. Alternatively, the thermoset resin, release agent, andpetroleum distillate can be mixed together after being introduced intothe mixing chamber 200.

A plurality of tank lines 622 provide pathways from the plurality oftanks 610 to the mixing tank 620. Most preferably, the thermoset polymerflows from tank 612 through tank line 622 to the mixing tank 620 at arate of 131 pounds per hour. Most preferably, the release agent flowsfrom tank 614 through tank line 622 to the mixing tank 620 at a rate ina range between one and ten pounds per hour. In one embodiment, therelease agent flow rate can be 3.5 pounds per hour. Most preferably, thepetroleum distillate flows from tank 616 through tank line 622 at a rateof 16 pounds per hour. Most preferably, the release agent flows from thetank 618 through tank line 622 at a rate of 4 pounds per hour.Alternatively, any other suitable flow rates can be used. Preferably,the blend flows from the mixing tank 620 and is combined with thecatalyst from the catalyst tank 618 in a resin valve feed line 624 andforms the admixture. Alternatively, the catalyst can be added directlyto the mixing chamber 200 through a separate injection port (not shown).

The embodiment shown also includes a cyclone 700. The cyclone 700includes an entrance 710, an exit 720, and a middle portion 730. Themiddle portion 730 is disposed between the entrance 710 and the exit 720of the cyclone 700. The middle portion 730 includes at least one magnet(not shown). The exit 720 of the cyclone 700 is in fluid communicationwith the entrance 520 of the hopper 500. Preferably, cellulosic materialis introduced into the apparatus 100 through the entrance 710 of thecyclone 700. As the cellulosic material is directed from the entrance710 through the middle portion 730 and to the exit 720 of the cyclone700, the magnet removes ferrous material that is present in thecellulosic material. The process of making the cellulosic-basedcomposite material will next be described.

FIG. 5 shows a flowchart of a process of using the apparatus shown inFIG. 1 and described above. As indicated by blocks 805 and 810 in FIG.5, the method of making a material composition shown preferably includesmixing a thermoset polymer, petroleum distillate, and a release agent,and with combining a catalyst to form an admixture 815. Alternatively,the catalyst can be combined with the cellulosic material directly. Asindicated by block 820, the admixture 815 mixes with a cellulosicmaterial 816 in the mixing chamber 200 to form a generally homogenousfurnish 825. Most preferably, the thermoset is present in the furnish inan amount of 6 to 10 percent by weight. Preferably, the thermosetpolymer is a melamine urea formaldehyde resin. A thermoset polymer is apolymer that does not melt when heated after initial hardening, incontrast to a thermoplastic polymer. Alternatively, any other suitablethermoset can be used. In one embodiment, the chiller 250 maintains theadmixture and the cellulosic material at a temperature of 65 degrees F.In one embodiment, the petroleum distillate is preferably an emulsifiedwax. Alternatively, the petroleum distillate can be any other suitableemulsified wax. Most preferably, the release agent is a modified fattyoil commercially available from E.U.P. Wurtz GmbH & Co. (product No.PAT-2660). In one embodiment, the release agent is preferably a modifiedfatty oil. Release agents are also known as separators, parting agents,or parting compounds. Other release agents that can be used areemulsified waxes, montan waxes, and zinc sterates. Common release agentsinclude soft liquids, such as soap, petroleum jelly, or thin oils.Alternatively, the release agent can be any other suitable lubricantcommonly used in extrusion of wood and plastics. In one embodiment, thecatalyst is ammonium chloride. Alternatively, the catalyst can be anyother suitable catalyst, such as ammonium sulphate or aluminum sulphate.

In an embodiment, the cellulosic material most preferably includesdiscrete wood particles. Preferably, wood fiber is not used. Preferably,the cellulosic material can vary significantly in size, shape, weight,moisture content, and material type. Alternatively, the cellulosicmaterial can be any other suitable plant-like material. Preferably, thesource of the wood particles is from waste wood, including waste woodfrom manufacturing processes, e.g., manufacturing doors. Alternatively,the wood particles can be from any other suitable source. Preferably, adiameter of each of the wood particles is less thanone-eighth-of-an-inch. Alternatively, the diameter of each of the woodparticles can be less than three-eighths-of-an-inch.

In an embodiment, the cellulosic material preferably is present in thefurnish in the amount of 83 to 93.5 percent by weight. The petroleumdistillate is present in the furnish in the amount of 0 to 2 percent byweight. The release agent is present in the furnish in the amount of0.03 to 0.5 percent by weight. The catalyst is present in the furnish inthe amount of 0.5 to 3 percent by weight. Alternatively, any othersuitable amounts for the above can be used.

In an embodiment, the input chute 410 of the die introduces thehomogenous furnish 825 into a volume 442 of the die 400 as indicated byblock 830. Preferably, the furnish is introduced into the die at apredetermined rate. Most preferably, the rate is 990 pounds per hour. Inan embodiment, the homogenous furnish, as indicated by block 840, isheated to a temperature of at least 212 degrees F. Preferably, theheating elements 450 of the die 400 heat the furnish. Accordingly, theheat provided by the heating elements vaporizes water present in thefurnish. In one embodiment, the water vapor is released from thehomogenous furnish as indicated by block 850. The structure of theheating elements and the grooves and orifices allowing the release ofthe vapor in the platens is described in detail above. Preferably, anyother suitable means for vapor release can be used.

In an embodiment, the die 400 compresses the homogenous furnish to auniform density in the range between approximately 27 and approximately36 pcf, as indicated by block 860. Most preferably, the homogenousfurnish is compressed by the platens in the die 400. Alternatively,compressing the homogenous furnish can be performed by any othersuitable means. In an embodiment, as indicated by block 870, the forceof the piston 430 continuously displaces the homogenous furnish alongthe length of the die. Alternatively, the homogenous furnish can bedisplaced along the length of the die by any other suitable means. Thecomposite material is thus formed continuously.

The continuously formed composite material can be further processedafter it exits the output channel 420. For example, the compositematerial can be sanded, shaped, and cut as desired. The compositematerial can be used in a variety of applications, including thosesuitable for particleboard. For example, the composite material can beused in hollow-core or solid-core doors for lockblocks, rails, stiles,and the like.

An exemplary embodiment of an application for the composition describedabove is shown in FIG. 6. A hollow paneled door 900 includes afront-facing outer skin 910 with a series of molded panels 912 and arear-facing outer skin (not shown). Preferably, the frontfacing outerskin 910 and the rear-facing outer skin are adhered together by a toprail 920, a bottom rail 922, a latch stile 930, and a hinge stile 932,all of which are indicated in dotted line.

Also shown in dotted line is a lockblock 940. The lockblock 940 isproduced by the apparatus and the method described above. Preferably,the lockblock 940 is adhered to the latch stile 930. Alternatively, thelockblock 940 can be joined to the latch stile 930 by any other suitablemeans, such as by using a threaded fastener. A through hole 950 forseating a latch set (not shown) extends through the front-facing outerskin 910 and the rear-facing outer skin and the lockblock 940. Thelockblock 940 provides a surface for adhering the front-facing exteriorskin 910 and the rear-facing exterior skin. The lockblock 940 furtherprovides reinforcement for the latch set and the door 900. Whiledimensions for the lockblock 940 can vary, the preferred dimensions forthe lockblock 940 are three inches by six-and-three-quarters of an inchby one-and-one-eighth of an inch. Alternatively, the dimensions of thelockblock can be three inches by sixteen inches by one-and-one-eighth ofan inch.

Most preferably, the top rail 920, the bottom rail 922, the latch stile930, the hinge stile 932, and the lockblock 940 are made of thedisclosed composite material. Most preferably, the composite material ismade in accordance with the disclosed system and method. Alternatively,any other suitable system and method can be used to produce thedisclosed composite material for use in a hollow paneled door.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations, and changes to thedescribed embodiments are possible without departing from the sphere andscope of the present invention, as defined in the appended claims.Accordingly, it is intended that the present invention not be limited tothe described embodiments, but that it has the full scope defined by thelanguage of the following claims, and equivalents thereof.

1. An apparatus for forming a continuous cellulosic-based compositematerial comprising: a mixing chamber comprising a volume and at leastone entrance and an exit; a feeding chamber comprising a volume, anentrance, and an exit, the entrance of the feeding chamber being influid communication with the exit of the mixing chamber; and a diecomprising an entrance, an exit, a piston, a ram, and a pressingchamber, the entrance of the die being in fluid communication with theexit of the feeding chamber, the pressing chamber having a volume formedby first and second platens, the first and second platens being disposedin facing opposition to one another and having a length extendingcontinuously from at least the entrance of the die to the exit of thedie, the first and second platens having a plurality of orifices andheating elements disposed along the length, the first and second platensbeing disposed in first and second positions, the first position forminga first volume and the second position forming a second volume.
 2. Theapparatus according to claim 1, wherein the reciprocating ram displacesa predetermined amount of a workpiece through the volume of the pressingchamber at a continuous rate.
 3. The apparatus according to claim 2,wherein the continuous rate is approximately 990 pounds per hour.
 4. Theapparatus according to claim 3, wherein the entrance of the diecomprises an input chute.
 5. The apparatus according to claim 4, whereinthe workpiece is introduced into the volume of the pressing chamberthrough an input chute.
 6. The apparatus according to claim 1, wherein adistance between the first and second platens in the first position is afirst distance.
 7. The apparatus according to claim 6, wherein adistance between the first and second platens in the second position isa second distance.
 8. The apparatus according to claim 7, wherein thesecond distance is greater than the first distance.
 9. The apparatusaccording to claim 1, wherein ends of the first and second platens inthe first position are proximate the entrance of the die.
 10. Theapparatus according to claim 1, wherein ends of the first and secondplatens in the second position are proximate the exit of the die. 11.The apparatus according to claim 1, wherein a spacer is disposed betweenthe first and second platens.
 12. The apparatus according to claim 1,wherein the spacer has a first end and a second end, the first endproximate the entrance of the die and the second end proximate the exitof the die, the first end of the spacer having a first thickness and thesecond end of the spacer having a second thickness.
 13. The apparatusaccording to claim 12, wherein the second thickness is greater than thefirst thickness.
 14. The apparatus according to claim 1, wherein thefirst volume is greater than the second volume.
 15. The apparatusaccording to claim 1, wherein the piston is disposed proximate theentrance of the die and opposite the exit of the die.
 16. The apparatusaccording to claim 5, wherein the piston is positioned substantiallyperpendicular to the input chute.
 17. The apparatus according to claim16, wherein the ram is coupled to the piston.
 18. The apparatusaccording to claim 17, wherein the ram comprises a face, the facecontacting the workpiece.
 19. The apparatus according to claim 18,wherein the face comprises a serrated edge.
 20. The apparatus accordingto claim 18, wherein the face comprises a flat edge.
 21. The apparatusaccording to claim 3, wherein the piston exerts a force on the workpiecesubstantially planar to the length of the first and second platens. 22.The apparatus according to claim 21, wherein the force of the pistondisplaces the workpiece toward the exit of the die at the continuousrate.
 23. The apparatus according to claim 2, wherein the first andsecond platens compress the workpiece to a substantially uniformdensity.
 24. The apparatus according to claim 23, wherein the density isin a range between approximately 27 and approximately 36 pounds percubic foot.
 25. The apparatus according to claim 1, wherein the firstand second platens each have a thickness, wherein the plurality oforifices are formed through the thickness of the first and secondplatens.
 26. The apparatus according to claim 1, further comprising: ahopper comprising a volume, an entrance, an exit, and a screw feederdisposed proximate the exit of the hopper, the exit of the hopper beingin fluid communication with one of the entrances of the mixing chamber;and a resin injector comprising at least one tank and a regulatingvalve, the regulating valve being in fluid communication with anotherone of the entrances of the mixing chamber.
 27. The apparatus accordingto claim 26, wherein the hopper further comprises a screen having aplurality of orifices, the orifices each having a diameter.
 28. Theapparatus according to claim 27, wherein the diameter is in a rangebetween approximately one-eighth of an inch and approximatelythree-eighths of an inch.
 29. The apparatus according to claim 27further comprising: a cyclone having an entrance, an exit, and a middleportion, the middle portion being disposed between the entrance and theexit of the cyclone and including at least one magnet, the exit of thecyclone being in fluid communication with the entrance of the hopper,wherein cellulosic material is directed from the entrance of the cycloneto the exit of the cyclone passing through the middle portion, wherebythe at least one magnet removes ferrous material from the cellulosicmaterial.